An ISO 9001:2015 company

TECHNICAL DATA
Ambient Curable Polyethylene Compound For Insulation Of Low
Voltage Power Cable With High Line Speed : KI – XL – 03 HS / KI – SC – 10 HS

DESCRIPTION:
KIL’s Polyethylene Compound XL – 03HS is a superior grade of silane pre-grafted low density
Polyethylene Compound. It is designed to be used as insulation of low Voltage Power Cable. Keeping
in mind the stringent quality requirements, special attentions are paid to maintain dust free
environment during its manufacture. An enriched additive package makes it highly scorch retardant
and protects it against heavy metal induced degradation.

KI-XL-03HS is to be used in conjunction with KI-SC-10HS, which contains a catalyst activator to

enhance the process of cross-linking in open environment, (no needs of sauna, CV tube or steam bath)
and special process aid to enhance the line speed without much of die drool.

These two components XL-03HS & KI-SC-10HS are inert, when stored in a cool & dry place.
However when mixed, extruded and exposed to moisture cross-linking takes place rapidly. The
components are therefore to be mixed just before consumption, usually in the ratio of 95 parts of
Grafted Polymer (XL-03HS) to 5 part of Catalyst Master Batch (KI-SC-10HS).

Such system allows the compound to be extruded as normal thermoplastic in a conventional PE

extrusion line. In each case time of curing is to be optimized as a function of thickness of insulation,
concentration of catalyst and atmosphere humidity.
SPECIFICATIONS :
KI-XL-03 HS & XL-SC10 HS meets requirements as applicable under following standards, when
processed using sound extrusion practice and testing procedure;

• IS 10810 , BS 5467, 5468, 6724, 7655 & IEC 60502

TYPICAL PROPERTIES :
A) XL-03HS
Property Unit Typical Value Test Method
Density gm / cm3 0.922 – 0.925 ASTM-D-792
IS-10810 (Part-23) /
Melt Flow Index (190°C, 2.16 Kg) gm / 10 Min 0.8 – 1.5
ASTM-D-1238
Contamination (Visual) No./Kg <5 KIIL

B) XL-03HS / KI-SC-10HS Combination

Mixed in proportion of 95:5 and extrude a tape of 1.0 mm thickness. Extruded tape kept in open
environment (Relative humidity  60 – 70 & temperature 27 – 30°C) for 24 hrs where cross-linking
takes place.

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 Typical
Property Unit Test Method
Value
IS-10810 (Part-7)
Tensile Strength MPa 14 - 16
/ ASTM-D-638
IS-1081 (Part-7) /
Elongation at break % 400 – 600
ASTM-D-638
Hot set at 200 °C
a) Hot Elongation after 15 min. % 80 – 100 IS-10810 Part-30
/ IEC 60811-507
b) Permanent Set after 5 min % +5 -- do --
Oven ageing at 135 °C, 168 hours
a) Variation in Tensile Strength % + 15 IS-10810 Part-11
/ IEC 60811-401
b) Variation in Elongation at Break % + 15 IS–10810 Part-11
/ IEC 60811-401
Volume Resistivity Ohm-cm 1 X 1016 ASTM-D-257
Dissipation factor
- 0.0004 ASTM-D-150
@ 250V / 50 Hz, 25°C
Dielectric Constant
- 2.1 – 2.3 ASTM-D-150
@ 250V / 50Hz, 25°C

CROSSLINKING WITH AMBIENT CURING CATALYST M. B. (KI-SC-10HS).

The time of cross-linking of the insulation usually dependent on the following factors:
 Catalyst concentration.
 Relative humidity.
 Temperature.
 Insulation thickness

Polyethylene absorbs water very slowly, that means insulation thickness has a relatively large
influence on cross-linking speed.

Relative Temperature Insulation Thickness Time to reach 100%

humidity % °C mm hot elongation, days
50 27 0.7 2
50 27 1.0 5
50 27 1.2 7

It is evident from the above table, the grafted polymer and catalyst master batch makes it
possible to crosslink with in a practical condition and acceptable time frame even at ambient
temperature with radial thickness upto 1.2mm. In practice, the addition of water to the cable
core drum by spraying further reduces curing time. For radial thickness above 1.2mm the
actual time taken should be ascertain by actual trial before bulk production.

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PROCESSING GUIDELINES:

1. It is recommended to dry the Catalyst Master Batch and suitable colour Master Batch
at 60°C in air oven in 4 – 6 cm Layers for 8 – 12 hours. The Grafted Polymer should
never be pre-heated.

2. The Grafted Polymer and Catalyst Master batch should be manually mixed at a ration
of 95:5 at room temperature without shearing, just before consumption. Mixing in
large quantities should be avoided, since such leftover premix cannot be stored.

3. During extrusion, following temperature profile is suggested:

Position Temperature (°C)

Barrel 150 - 170
Head 175 - 180
Die 190 - 195

To get maximum output (line speed), some adjustment in temperature profile and
tooling size selection to be arrived by trial, depending on size and type of extruder and
cable.

4. Recommended start-up procedure is given below:

a. Ensure that the screw, barrel and tools are thoroughly cleaned.

b. Start up slightly lower temperature profile. Allow the frictional heat to build-
up to desired temperature and remain steady thereafter.

c. Flush with virgin LDPE (film grade). Adjust eccentricity and wall thickness
inserting conductor.

d. Replace LDPE with XL-03HS / KI-SC-10HS premix. Increase line speed to

optimum. Adjust temperature to obtain a smooth surface finish.

e. Avoid thermal shock by sudden cooling. Keep sufficient distance between die-
head and water trough to allow air cooling. Avoid inlet water being too cold.

5. It is important that extruder should not be kept idle for more that 15 minutes when
filled premix compound.

6. During tubing extrusion, build-up of stress should be avoided; size of the core point
should be carefully selected to keep the Draw Down Ratio (DDR) below 2:1 in case
of small sizes. For higher sizes of the core, DDR may be increased slightly. It is also
recommended that land be in place, with its length approximately same as that of the
finished diameter of the core.

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PACKAGING :

 Moisture Barrier Multilayer Bags of 25 kg.

 20’ FCL will take palletized 11 MT & 40’ will take 24.75 MT.

STORAGE :

The shelf life of the product is 3 months from the date of production, subject of following
conditions:

 Storage temperature not generally exceeding 25°C

 Away from direct sunlight and weathering.
 Closed and unbroken bags.
 Use of compound within 3-4 hours after bags are open.
 Bags should be kept on Wooden or Plastic pallets.

The information given in the document is believed to be reliable and is given in the good faith but
without warranty. The user should test the product to ascertain the suitability for the intended use.
Product specification or the whole document is subject to change without any prior notice.

MKT: TDS – 03/SC/10HS – 11/17

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